U.S. patent application number 10/741095 was filed with the patent office on 2004-08-19 for front end module.
Invention is credited to Brown, Mitch, Butterfield, Larry D., Gaida, Dennis, Goral, Thomas M., Klages, Jerry, Kowal, Eric, Longhouse, Blair, Nardone, Terry E., Panter, Keith R., Staargaard, James E..
Application Number | 20040160088 10/741095 |
Document ID | / |
Family ID | 32682124 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040160088 |
Kind Code |
A1 |
Staargaard, James E. ; et
al. |
August 19, 2004 |
Front end module
Abstract
A front end module is described, wherein the module includes a
plastic component connected to a metallic substrate. The metallic
substrate can be formed by hydroforming and shaped into a
substantially unitary member. The plastic component is then molded
about the metallic substrate and simultaneously forms connections
thereto at discrete locations along the length of the metallic
substrate.
Inventors: |
Staargaard, James E.;
(Farmington Hills, MI) ; Kowal, Eric; (Roseville,
MI) ; Goral, Thomas M.; (Oakland Township, MI)
; Brown, Mitch; (Laingsburg, MI) ; Panter, Keith
R.; (Ann Arbor, MI) ; Butterfield, Larry D.;
(Canton, MI) ; Longhouse, Blair; (Otterville,
CA) ; Klages, Jerry; (Woodstock, CA) ;
Nardone, Terry E.; (Waterford, MI) ; Gaida,
Dennis; (Clarkston, MI) |
Correspondence
Address: |
Richard W. Hoffmann
PO Box 70098
Rochester Hills
MI
48307
US
|
Family ID: |
32682124 |
Appl. No.: |
10/741095 |
Filed: |
December 19, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60434923 |
Dec 19, 2002 |
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60434932 |
Dec 19, 2002 |
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Current U.S.
Class: |
296/193.09 |
Current CPC
Class: |
B29L 2031/30 20130101;
B62D 29/004 20130101; B62D 25/084 20130101; B29C 45/14344 20130101;
B29C 2045/14327 20130101; B62D 29/001 20130101; B29C 45/1418
20130101; B29L 2031/3002 20130101 |
Class at
Publication: |
296/193.09 |
International
Class: |
B60J 007/00 |
Claims
What is claimed is:
1. A front end module, comprising; a metallic component having at
least one opening formed therein; and a plastic component disposed
about at least a portion of the metallic component, wherein a first
portion of the plastic material extends through the at least one
opening and a second portion of the plastic material extends about
an external surface of the metallic component so as to connect the
plastic component to the metallic component.
2. The invention according to claim 1, wherein the metallic
component is formed by hydroforming.
3. The invention according to claim 1, wherein the metallic
component is a contoured unitary member.
4. The invention according to claim 1, wherein the metallic
component includes a horizontal portion and two spaced and opposed
vertical portions extending therefrom.
5. The invention according to claim 1, wherein the metallic
substrate comprises a closed cross section.
6. The invention according to claim 1, wherein the metallic
component includes a plurality of openings formed therein.
7. The invention according to claim 1, wherein the plastic
component includes at least one opening formed therein.
8. The invention according to claim 1, wherein the plastic
component includes a plurality of openings formed therein.
9. The invention according to claim 1, wherein the plastic
component includes at least one attachment hole formed therein.
10. The invention according to claim 1, wherein the plastic
component includes at least one reinforcement member formed a
surface thereof.
11. A front end module, comprising; a contoured unitary metallic
component having at least one opening formed therein; and a plastic
component disposed about at least a portion of the metallic
component, wherein a first portion of the plastic material extends
through the at least one opening and a second portion of the
plastic material extends about and envelopes an external surface of
the metallic component so as to connect the plastic component to
the metallic component.
12. The invention according to claim 11, wherein the metallic
component is formed by hydroforming.
13. The invention according to claim 11, wherein the metallic
component includes a horizontal portion and two spaced and opposed
vertical portions extending therefrom.
14. The invention according to claim 11, wherein the metallic
substrate comprises a closed cross section.
15. The invention according to claim 11, wherein the metallic
component includes a plurality of openings formed therein.
16. The invention according to claim 11, wherein the plastic
component includes at least one opening formed therein.
17. The invention according to claim 11, wherein the plastic
component includes a plurality of openings formed therein.
18. The invention according to claim 11, wherein the plastic
component includes at least one attachment hole formed therein.
19. The invention according to claim 11, wherein the plastic
component includes at least one reinforcement member formed a
surface thereof.
20. A front end module, comprising; a contoured unitary metallic
component having at least one opening formed therein, wherein the
metallic component includes a horizontal portion and two spaced and
opposed vertical portions extending therefrom; and a plastic
component disposed about at least a portion of the metallic
component, wherein a first portion of the plastic material extends
through the at least one opening and a second portion of the
plastic material extends about and envelopes an external surface of
the metallic component so as to connect the plastic component to
the metallic component.
21. The invention according to claim 20, wherein the metallic
component is formed by hydroforming.
22. The invention according to claim 20, wherein the metallic
substrate comprises a closed cross section.
23. The invention according to claim 20, wherein the metallic
component includes a plurality of openings formed therein.
24. The invention according to claim 20, wherein the plastic
component includes at least one opening formed therein.
25. The invention according to claim 20, wherein the plastic
component includes a plurality of openings formed therein.
26. The invention according to claim 20, wherein the plastic
component includes at least one attachment hole formed therein.
27. The invention according to claim 20, wherein the plastic
component includes at least one reinforcement member formed a
surface thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The instant application claims priority to U.S. Provisional
Patent Application Serial No. 60/434,923, filed Dec. 19, 2002, the
entire specification of which is expressly incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to components
comprised of metallic and plastic content, and more particularly to
front end modules including a plastic material connected to a
metallic substrate.
BACKGROUND OF THE INVENTION
[0003] Currently, structural components for vehicles, such as
vehicle front end modules and door supports are made of metal
and/or plastic. Front end modules provide structure to the vehicle
as well as providing attachment structure for various vehicle
components, such as the headlamps, radiator, fan, horn, and the
like. Preferably, the front end modules can be provided in a single
unit assembly, which is ready to be mounted to the vehicle by the
manufacturer.
[0004] Commonly, such structural components are made from several
stampings that are welded together. Alternatively, such components
have been made from closed section metal, such as by extrusion or
hydroforming. The use of closed section metal provides a relatively
stronger component. Typically, however, additional metal material
must be welded to the closed section metal components to provide
for attachment surfaces.
[0005] These structural components are not currently made entirely
from plastic material for larger vehicles because of the inability
to meet vehicle performance requirements. However, use of plastic
components in conjunction with metal to provide attachment points
for the vehicle components is known in the art. In some instances,
the metal structural component is attached to the plastic component
with mechanical fasteners, such as screws or rivets. But, the use
of this method is relatively cost and labor intensive.
[0006] Another method of securing the plastic to the metal
structure is shown in U.S. Pat. No. 6,273,496 to Guyomard et al.
and assigned to Valeo Thermique Moteur. This reference appears to
disclose a front panel that includes metal structural components,
including a closed section metal component. A plastic material is
overmolded over the metal structure.
[0007] Another method of securing plastic to metal is shown in U.S.
Application Publication No. 2001/0053431 to Goldbach et al. in the
name of Bayer Corporation. Another such plastic and metal part is
shown in U.S. Pat. No. 5,190,803 to Goldbach and assigned to Bayer
Akhengesellsschaft.
[0008] Accordingly, there exists a desire for front end modules
that include a plastic component attached to a metallic substrate,
especially wherein the plastic component can be connected to the
metal substrate during fabrication without the use of mechanical
fasteners while also using a relatively small amount of plastic
material to achieve the connection.
SUMMARY OF THE INVENTION
[0009] In accordance with a first embodiment of the present
invention, a front end module is provided, comprising a metallic
component having at least one opening formed therein. The module
further comprises a plastic component disposed about at least a
portion of the metallic component, wherein a first portion of the
plastic material extends through the at least one opening and a
second portion of the plastic material extends about an external
surface of the metallic component so as to connect the plastic
component to the metallic component.
[0010] In accordance with another embodiment of the present
invention, a front end module is provided, comprising a contoured
unitary metallic component having at least one opening formed
therein. The module further comprises a plastic component disposed
about at least a portion of the metallic component, wherein a first
portion of the plastic material extends through the at least one
opening and a second portion of the plastic material extends about
and envelopes an external surface of the metallic component so as
to connect the plastic component to the metallic component.
[0011] In accordance with another embodiment of the present
invention, a front end module is provided, comprising a contoured
unitary metallic component having at least one opening formed
therein, wherein the metallic component includes a horizontal
portion and two spaced and opposed vertical portions extending
therefrom. The module further comprises a plastic component
disposed about at least a portion of the metallic component,
wherein a first portion of the plastic material extends through the
at least one opening and a second portion of the plastic material
extends about and envelopes an external surface of the metallic
component so as to connect the plastic component to the metallic
component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A further understanding of the present invention will be had
in view of the description of the detailed description of the
preferred embodiments, when viewed in conjunction with the
accompanying drawings wherein:
[0013] FIG. 1 is a front perspective view of a front end module, in
accordance with the general teachings of the present invention;
and
[0014] FIG. 2 is a rear perspective view of the front end module
depicted in FIG. 1, in accordance with the general teachings of the
present invention.
[0015] The same reference numerals refer to the same parts
throughout the various Figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0017] For example, although the following description primarily
describes the present invention in connection with a front end
module, it is to be appreciated that the present invention is
likewise applicable to all applications wherein it is desired to
connect a plastic component to a metallic component without the
need for separate fasteners.
[0018] With reference to the Figures, a composite front end module
in accordance with the general teachings of the present invention
is generally shown at 10.
[0019] The front end module 10 is preferably comprised of a single
(e.g., unitary) metallic member, such as, but not limited to, a
tube generally indicated at 12 (which is preferably manufactured by
hydroforming) that is preferably joined to a plastic component,
such as but not limited to a panel generally indicated at 14.
[0020] Preferably, the tube 12 comprises a closed cross section.
The use of such closed cross section metal components provides
rigidity to the module 10. The closed form section can take any
suitable configuration. It need not necessarily have a constant
cross sectional shape. Such structures are particularly useful for
vehicle support structures. It will be understood that open
cross-section metal components may also be used within the scope of
the present invention. The tube 12 may comprise any suitable metal,
such as but not limited to steel, aluminum, and the like.
[0021] The tube 12 can be configured in any number of
configurations. However, those configurations that are suitable for
use in front end modules are preferred. By way of a non-limiting
example, the tube 12 preferably begins at the upper area of the
module and is adapted to be connected to a vehicle structure such
as a fender (not shown). The tube 12 extends generally horizontally
as shown over the area corresponding to the headlamp module area or
mount 16. The tube 12 then turns and runs generally vertically down
roughly parallel with the area corresponding to the location of the
side of the radiator (not shown). The tube 12 then turns to run
generally horizontally and parallel with the area corresponding to
the location of the bottom of the radiator (not shown). The tube 12
then turns to run generally vertically and upward roughly parallel
with the opposite side of the area corresponding to the location of
the radiator (not shown). The tube 12 then turns to run generally
horizontally and over the opposing headlamp module area or mount 16
and ends at the opposite fender (not shown). As shown in FIGS. 1
and 2, the tube 12 generally comprises a u-shaped member with
extensions 28 extending outwardly from each arm of the u-shaped
member. Again, it is preferred that the tube 12 be formed as a
one-piece closed cross-section member such as by hydroforming.
[0022] The plastic panel 14 can be configured in a number of
suitable configurations. However, those configurations that are
suitable for use in front end modules are preferred. By way of a
non-limiting example, the plastic panel 14 preferably comprises an
upper cross member 18, headlamp mount 16, grill support 20, hood
latch mount 22, vertical center support 24, and the like. The
plastic panel 14 may also comprise at least one, and more
preferably a plurality of reinforcement members, e.g.,
strengthening ribs 26. As shown, the plastic panel 14 is preferably
contoured to allow for attachment of the aforementioned components,
and the like, and also may be provided with additional surface
effects, such as but not limited to openings, flanges, bosses, and
other protuberances.
[0023] The plastic panel 14 is preferably made from any suitable
thermoplastic or thermoset material. One such example of a plastic
material may comprise modified polyphenolene oxide. While one
example of a suitable plastic is provided, it will be appreciated
that any suitable thermoplastic or thermoset may be used within the
scope of the present invention. Further, fillers or other additives
may be added to the plastic material to strengthen the plastic
panel 14. Any suitable filler may be used. Such fillers may
comprise, for example, glass fiber or plastic fiber.
[0024] The extensions 28 of the front end module 10 are preferably
fixed to the upper front end of the fenders through the ends 30 of
the extensions 28 of the tube 12. The ends 30 of the extensions 28
of the tube 12 can preferably include openings for receiving
fasteners to secure the module 10 with the vehicle fenders. The
lower portion of the tube 12 preferably joins to the vehicle
chassis in two places through brackets (not shown) attached to the
tube 12 at attached points 32.
[0025] The front end module 10 preferably locates the fenders and
provides a structural load path from the fenders to the vehicle
chassis. The front end module 10 also preferably locates and
supports the loads created by the cooling module by way of integral
mounting supports 34. The front end module is also adapted to
support a variety of other components such as, but not limited to
an air filter housing, A/C receiver dryer, headlamp module, coolant
reservoir, fan shroud, and horn which can also preferably be
mounted to the front end module 10. Mounting holes 36 can be
provided to mount these components and the like.
[0026] Tube 12 is preferably manufactured by first forming and
piercing a tube, preferably by hydroforming. The tube 12 is then
placed in an injection molding tool. The mold is then closed,
wherein plastic material, preferably including reinforcement, such
as glass fibers, is pumped into the cavity of the injection molding
tool thus forming the panel 14 into the desired configuration and
simultaneously joining it to the tube 12 at discrete locations
generally indicated at 38 leaving the remainder of the tube's 12
front and back surface exposed. More specifically, in order to join
the tube 12 to the panel 14, an opening (not shown) is formed on
one side of the tube 12. An opposite opening 40 is formed on the
opposite side of the tool. A core tool is inserted through the
opening 40 and adjacent the opening on the opposite side of the
tube 12. The core tool provides a cavity that allows the plastic
material to flow from one side of the tube 12 through the opening
into the cavity of the core tool. In this manner, plastic flows
through the opening, but does not fill the entire cavity of the
tube 12.
[0027] Preferably, the plastic material forms a button-like
structure 42 on the inside of the tube. This button-like structure
42 has edges that extend over the opening in the tube 12. The
plastic material forms on the opposite side of the tube 12 from the
opening 40 and may include strengthening ribs 26. With the
connection in this manner, plastic is secured to the tube 12
without the need to fully fill the tube 12 with plastic material.
Thus, the plastic material preferably infiltrates, at least
partially, into the tube 12 at locations 38 and, after cooling,
forms a connection point with the tube 12. A connection securing
the plastic panel 14 with the tube 12 is shown at 38 and is fully
described in U.S. Patent Application Serial No. 60/398,901, by the
same inventors hereto, and is incorporated herein by reference. It
will be appreciated that the connections at the locations 38 can be
configured in any number of forms, and can include, without
limitation, depressions, openings, holes, apertures, bores, through
bores, and the like.
[0028] Further, as shown, the plastic material can preferably be
formed around the tube 12, as shown at 44. Strengthening ribs 26
may also be included as set forth above. With connection made in
this manner, the plastic material preferably forms around the outer
surface of the tube 12 and, after cooling, forms a connection point
with the tube 12. Further, the connection made in this manner, by
molding the plastic panel 14 to tube 12, the need for separate
fasteners to connect the plastic components of the metal substrate
is eliminated. It will be appreciated, however, that separate
fasteners may be included in addition to the connection system set
forth above.
[0029] While injection molding is the presently preferred method of
making the module 10, it will be appreciated that any other
suitable forming technique may be uses within the scope of the
present invention. These include, without limitation, compression
molding, injection compression molding, extrusion compress, gas
assist or water assist pressure molding, low pressure molding, blow
molding, thermoforming and/or rotational molding.
[0030] Those skilled in the art can now appreciate from the
foregoing description that the broad teachings of the present
invention can be implemented in a variety of forms. Therefore,
while this invention has been described in connection with
particular examples thereof, the true scope of the invention should
not be so limited, since other modifications will become apparent
to the skilled practitioner upon a study of the drawings,
specification and appended claims.
* * * * *